Adjustable and Removable Keel Assembly and Blade Guide for a Jigsaw

ABSTRACT

A method of positioning a shoe member and a keel assembly relative to a housing of a jigsaw is provided. The method may include securing the keel assembly to the housing so that the keel assembly extends from the housing beyond the shoe member. The housing and the keel assembly may be pivoted relative to the shoe member in a manner such that a position of the housing relative to the keel assembly remains unchanged. A portion of the keel assembly may be uncoupled from the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No. 11/859,172, filed Sep. 21, 2007. The disclosure of the above application is incorporated herein by reference.

FIELD

The present teachings relate to a jigsaw and more particularly relate to an adjustable and removable keel attachment that can remain in line with a housing of the jigsaw, while a shoe member is pivoted relative to the housing.

BACKGROUND

Typically, a keel blade can be attached to a jigsaw to provide a relatively more accurate straight cut through a piece of sheet material than a jigsaw without the keel blade. The keel blade is traditionally attached to and removed from a housing of the jigsaw using tools and multiple fasteners, which can be a relatively complex process. In some instances, the keel blade needs to be uncoupled from the housing to perform a bevel cut.

SUMMARY

The present teachings generally include a jigsaw that includes a housing containing a motor activated by a trigger assembly. A shoe member is pivotally connected to the housing and establishes an angle therebetween. The jigsaw includes a keel assembly that includes a blade member that generally extends from the housing beyond the shoe member. The keel assembly remains generally in line with the housing as the angle between the shoe member and the housing varies. The jigsaw also includes a latch assembly capable of retaining and releasing the keel assembly from the housing.

In another form, the present disclosure provides a method of positioning a shoe member and a keel assembly relative to a housing of a jigsaw. The method may include securing the keel assembly to the housing so that the keel assembly extends from the housing beyond the shoe member. The housing and the keel assembly may be pivoted relative to the shoe member in a manner such that a position of the housing relative to the keel assembly remains unchanged. A portion of the keel assembly may be uncoupled from the housing.

In yet another form, the present disclosure provides a method of positioning a keel assembly and a lower carrier assembly relative to a housing of a jigsaw, the lower carrier assembly having a lower blade guide. The method may include connecting the keel assembly to the housing so that the keel assembly extends from the housing beyond a shoe member. The keel assembly may be pivoted relative to the housing. A position of the lower carrier assembly may be adjusted relative to the keel assembly.

In yet another form, the present disclosure provides a method that may include providing a jigsaw having a housing, a shoe member, and a keel assembly. The shoe member may be coupled to the housing and may be adapted to support the jigsaw on a surface of a workpiece. The keel assembly may extend from the housing beyond the shoe member. The method may also include connecting a carrier assembly to the keel assembly. The carrier assembly may have a lower blade guide that is adapted to support a blade member. The carrier assembly may be moved relative to the keel assembly from a first position to a second position. The carrier assembly may be secured to the keel assembly in the second position.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present teachings.

DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present teachings.

FIG. 1 is a perspective view of a jigsaw having a keel assembly attached to a housing of the jigsaw in accordance with the present teachings.

FIG. 2 is an exploded assembly view of the keel assembly including a lower carrier assembly that can be repositioned relative to a blade member of the keel assembly to provide support for a rear edge of a cutting blade in accordance with the present teachings.

FIG. 3 is a side view of a front connection portion of the keel assembly and a front connection portion of the housing to where the front connection portion of the keel assembly is retained when the keel assembly is coupled to the housing in accordance with the present teachings.

FIG. 4 is a partial cross-sectional side view of a rear connection portion of the keel assembly that can connect to and pivot about a rear connection portion of the housing in accordance with the present teachings.

FIG. 5 is similar to FIG. 3 and shows the lower carrier assembly disposed at a different position relative to an upper carrier assembly in accordance with the present teachings.

FIG. 6 is a partial perspective view of a latch assembly in the front connection portion of the jigsaw housing that can be pressed or otherwise retracted to release a front connection portion of the keel assembly so that the keel assembly can be uncoupled from the housing in accordance with the present teachings.

FIG. 7 is a partial front view of a jigsaw having a keel assembly disposed at various angles relative to a shoe member to establish various cutting angles in accordance with the present teachings.

FIG. 8 is a simplified partial cross-sectional side view of a blade guide mechanism showing one of the two guide members that extend from an upper carrier assembly so as to terminate in a position that almost touches the sides of the cutting blade in accordance with a further aspect of the present teachings.

FIG. 9 is a simplified partial cross-sectional top view of the cutting blade and its position relative to hardened ends of the guide members of FIG. 8 in accordance with the present teachings.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present teachings, their application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

Moreover, certain terminology can be used for the purpose of reference only and do not limit the present teachings. For example, terms such as “upper,” “lower,” “above” and “below” can refer to directions in the drawings to which reference is made. Terms such as “front,” “back,” “rear” and “side” can describe the orientation of portions of the component, function, system, etc. within a consistent but arbitrary frame of reference which can be made more clear by reference to the text and the associated drawings describing the component, function, system, etc. under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof and words of similar import. Similarly, the terms “first,” “second” and other such numerical terms referring to structures, systems and/or methods do not imply a sequence or order unless clearly indicated by the context.

With reference to FIG. 1, a jigsaw 10 generally includes a housing 12 that can be formed of two half shells 14, 16. The housing 12 can contain a motor 18. When activated by a trigger assembly 20, the motor 18 can provide a reciprocating and/or pendulum motion to a cutting blade holder 22 on the end of a reciprocating shaft to drive a cutting blade 24 at one or more cutting angles 26 (FIG. 7). A control member 28 on a side of the housing 12 can control a rate of the reciprocation and/or a magnitude of the pendulum motion of the cutting blade holder 22 on the reciprocating shaft and thus the cutting blade 24.

A shoe member 30 can be coupled to a bottom 32 of the housing 12 in such a way as to permit the shoe member 30 to pivot relative to the housing 12. As the shoe member 30 pivots relative to the housing 12, the cutting blade holder 22, the cutting blade 24, etc., can be orientated at various angles (i.e., one or more of the cutting angles 26 (FIG. 7)) relative to the shoe member 30. A bottom surface 34 of the shoe member 30 can abut a workpiece 36, which can be wood, plastic, metal, other suitable materials and one or more combinations thereof and can be in the form of pipe, sheet material, stock material, other suitable forms and/or materials and one or more combinations thereof. The shoe member 30 can be pivoted relative to the housing 12 to adjust the cutting angle 26 (FIG. 7) of the jigsaw 10, e.g., at a forty-five degree cutting angle.

As the shoe member 30 is moved relative to the housing 12, an angle indicator wheel 38 can be rotatably coupled to the shoe member 30 and can indicate the cutting angle 26 of the jigsaw 10. Further, a locking mechanism 40 can include a bevel lever 42 that can be adjusted between an unlocked condition and a locked condition, as shown in FIG. 1. In the unlocked condition the locking mechanism 40 can permit the shoe member 30 to pivot relative to the housing 12. In the locked condition, as illustrated in FIG. 1, the locking mechanism 40 can prevent the shoe member 30 from pivoting relative to the housing 12. The cutting angle 26 (FIG. 7) to which the shoe member 30 can be pivoted relative to the housing 12, when the locking mechanism 40 is in the unlocked condition, can be indicated by the angle indicator wheel 38.

A dust extraction port 44 can be formed on a rear portion 46 of the shoe member 30 such that a vacuum source 48 can be connected with various suitable connections to the dust extraction port 44. A dust extraction airflow 50 can be extracted from a cutting area 52. From the cutting area 52, the dust extraction airflow 50 can move through an airflow pathway formed in the shoe member 30 and directed out of the dust extraction port 44.

The jigsaw 10 can include a laser module 80. The laser module 80 can project a laser light 82 and can produce a laser light pattern 84. The laser light pattern 84 can produce, for example, a sequence of dashes and/or dots beyond a front side 86 of the cutting blade 24 and can highlight a path of the cutting blade 24 through the workpiece 36.

The jigsaw 10 can also include a keel assembly 100 that can provide additional straight-line accuracy when cutting a straight line in the workpiece 36 (e.g., can help avoid wandering of the jigsaw cutting path). The keel assembly 100 can be pivoted with the housing 12 when the shoe member 30 is moved at an angle (i.e., the one or more cutting angles 26 (FIG. 7)) relative to the housing 12. In this regard, the shoe member 30 can be pivoted relative to the housing 12 but the keel assembly 100 can remain generally in line with the housing 12 so as to provide, for example, a straight bevel cut through the workpiece 36, i.e., the cutting angle is not perpendicular to the workpiece 36 but the cutting path through the workpiece 36 is straight.

The keel assembly 100 can be connected to the bottom 32 of the housing 12. The shoe member 30 can extend from the housing 12 beyond the shoe member 30 and distally outward (i.e., downward) from the bottom 32 of the jigsaw 10. The keel assembly 100 can include a keel blade member 102 to which a lower guide assembly 104 can be attached. The lower guide assembly 104 can be spaced at various predetermined distances from an upper guide assembly 106 that extends from the housing 12. By adjusting the lower guide assembly 104 relative to the upper guide assembly 106, the distance between the assemblies 104, 106 can be adjusted to accommodate workpieces having different thicknesses.

With reference to FIGS. 2 and 3, The keel assembly 100 can also include a front connection portion 108 that can have a flange 110 in which an aperture 112 can be formed. The keel assembly 100 can further include a rear connection portion 114 that can define a lip 116. A rear connection portion 118 in the housing 12 can accept the lip 116 of the rear connection portion 114. In this regard, the rear connection portion 114 of the keel assembly 100 can be received by the rear connection portion 118 of the housing 12 so that the lip 116 can pivot about the rear connection portion 118 of the housing 12.

As illustrated in FIG. 3, the keel assembly 100 can swing upwards so as to position the front connection portion 108 of the keel assembly 100 into engagement with a front connection portion 120 of the housing 12. The keel assembly 100 can also swing downwards when uncoupled from the housing 12 (illustrated in phantom line). When connecting the keel assembly 100 to the housing 12, the aperture 112 formed in the flange 110 can be accepted by a latch assembly 122 in the front connection portion 120 of the housing 12.

With reference to FIG. 6, the latch assembly 122 can include an actuator member 124 that can be pushed, retracted or the like. In one example, pushing the actuator member 124 into the latch assembly 122 can move a post 126 so as to move the post 126 out of the aperture 112 in the flange 110 of the front connection portion 108 of the keel assembly 100. By way of the above example, the actuator member can be pushed by one or more fingers, thumbs, etc. of the user. With reference to FIG. 3, with the front connection portion 108 no longer held by the latch assembly 122, the keel assembly 100 can swing downward about the lip 116 that can be held in the rear connection portion 118. As such, the keel assembly 100 can be uncoupled from the housing 12 via a hand operation and therefore no tools are required to do so.

In another example, pressing the actuator member 124 can release a bias on the post 126 so that the post 126 can move (e.g., retract) when the keel assembly 100 is pulled away from the housing 12. Notwithstanding the specific mechanism that can move the post 126, when the actuator member 124 is in the extended position (e.g., not pressed by a user), the post 126 can be held by the aperture 112 formed in the front connection portion 108 of the keel assembly 100 to secure the keel assembly 100 to the housing 12.

With reference to FIG. 7, the keel assembly 100 can be secured to the housing 12 and the keel assembly 100 can remain in-line with the housing 12, while the jigsaw 10 is moved relative to the shoe member 30 to establish the various cutting angles 26. The one or more cutting angles 26 of the cutting blade 24 (FIG. 1) of the jigsaw 10 are illustrated such that the cutting angle 26 (illustrated in solid line) is positioned at a zero degree cutting angle, i.e., a perpendicular cutting angle relative to the shoe member 30.

In further aspects, a cutting angle 130 (shown in phantom line) can be positioned at about positive fifteen degrees, while a cutting angle 132 (shown in phantom line) can be positioned at about negative thirty degrees. A cutting angle 134 (shown in phantom line) can be positioned at about positive forty five degrees. It will be appreciated in light of the disclosure that various cutting angles can be implemented including, but not limited to, those cutting angles illustrated in FIG. 7. In one aspect, the keel assembly 100 can be removed from the housing 12 regardless and at any of the cutting angles implemented.

With reference to FIGS. 2, 3 and 5, the keel blade member 102 can define a channel 150 in which the lower carrier assembly 104 can move to adjust the distance between the lower carrier assembly 104 and the upper carrier assembly 106. The lower carrier assembly 104 can include an adjuster mechanism 152. The adjuster mechanism 152 can include an adjuster member 154 that can be retracted against the bias of a spring 156. By moving the adjuster member 154, a plug member 158 having a cam surface 160 can move out of alignment with an edge 162 of the channel 150 formed in the keel blade member 102. When the cam surface 160 is moved out of alignment with the edge 162, the lower carrier assembly 104 can be moved between positions 164 relative to the keel blade member 102

In one aspect, the positions 164 can include a top position 166, as shown in FIG. 5 and a lower position 168, as shown in FIG. 3 and again illustrated in phantom line in FIG. 5. By way of the above example, the different positions 164 of the lower carrier assembly 104 can be configured to accommodate varying lengths 170 of the cutting blade 24 for certain applications. In turn, the different positions 164 of the lower carrier assembly 104 can be implemented to accommodate differently sized workpieces.

In another aspect, the plug member 158 can have a circular cam surface 172 that can be received by one of the pockets 174 formed from the edge 162 of the channel 150. While three pockets 174, i.e., a first pocket 176, a second pocket 178, a third pocket 180 are illustrated, it will be appreciated in light of the disclosure that varying amounts of the pockets 174 can be defined in the channel 150 in the keel blade member 102 and can be associated with the positions 164 of the lower carrier assembly 104.

By moving the cam surface 160 out of contact with the edge 162 of the channel 150 formed in the keel blade member 102, the lower carrier assembly 104 can be moved relative to the keel blade member 102 to one of the selected positions 164. At one of the selected positions 164, the adjuster member 154 can be moved to an extended condition so that the cam surface 160 of the plug member 158 can again come into contact with the edge 162 of the channel 150 and thus hold the lower carrier assembly 104 in the selected position.

With reference to FIG. 2, the lower carrier assembly 104 can include a pair of arm members 182 that can be fastened together with the keel blade member 102 in between the arm members 182. Each of the arm members 182 can include one or more apertures. For example, a rear aperture 184, a middle aperture 186 and a front aperture 188 can be formed on each of the arm members 182. The rear aperture 184 can accept a fastener 190 that can also be inserted into a groove 192 formed in the keel blade member 102. As the lower carrier assembly 104 is moved relative to the keel blade member 102, the fastener 190 can travel in the groove 192.

One of the middle apertures 186 can be an oversized aperture (relative to other apertures) 194 on one of the arm members 182 so as to accept the plug member 158. The opposed middle aperture 186 on the opposite arm member 182 can accept a portion of the adjuster member 154. In this arrangement, the adjuster member 154 can be inserted through the spring 156 that can be disposed between a surface 196 of one of the arm members 182 and a head 198 of the adjuster member 154. The adjuster member 154 can couple to the plug member 158 (e.g., with mechanical threads) to secure the spring 156 between the head 198 and the surface 196. The front aperture 188 can accept a fastener 200 that can rotatably hold a rolling member 202 between each of the arm members 182. The rolling member 202 can be configured with a groove 204 to accept a rear edge 206 (FIG. 3) of the cutting blade 24.

The keel assembly 100 can further include a keel block 230 that can attach to the keel blade member 102. The keel blade member 102 can define a first protrusion 232 and a second protrusion 234. The first protrusion 232 can include an aperture 236 while the second protrusion 234 can include a second aperture 238. A portion of the keel blade member 102, including the protrusions 232, 234 can be accepted within a groove 240 (shown in broken line) formed within the keel block 230. Fasteners 242 can be passed through apertures 244 formed in the keel block 230 and the apertures 236, 238 formed in the keel blade member 102 near the keel blade member 102 to the keel block 230. In turn, the keel block 230 can connect to the housing 12, as partially shown in FIG. 3.

With reference to FIGS. 8 and 9, an upper carrier assembly 300 can include a rolling member 302 or other suitable member that can abut a rear (i.e., non-cutting) edge 206 of the cutting blade 24 of the jigsaw 10 in accordance with further aspects of the present teachings. From the upper carrier assembly 300, two guide members 306 can extend and can terminate at a position that almost touches a side 308 of the cutting blade 24. At ends 310 of each of the guide members 306, a hardened portion 312 can be positioned so that when the cutting blade 24 contacts the guide members 306, the cutting blade 24 can contact the hardened portions 312. Each of the hardened portions 312 can be harder than the material of which the guide members 306 are comprised.

When the jigsaw 10 is cutting in a straight line and there is generally no twist imparted on the cutting blade 24, the sides 38 of the cutting blade 24 will not touch the hardened portions 312 of the guide members 306. In other instances, the cutting blade 24 can cut through a workpiece and twist can be imparted on the cutting blade 24 such that the twist of the blade can force the sides 308 of the cutting blade 24 into the hardened portions 312 of the guide members 306. In one example, twisting of the cutting blade 24 can be due to the cutting blade 24 following a grain of wood especially in wet (green) wood.

It may be shown that keeping the guide members 306 and especially the hardened portions 312 in close proximity to the sides 308 of the cutting blade 24 can reduce the twisting of the cutting blade 24 and reduce deviations from a straight cutting line. As such, the ends 310 of the guide members 306 can be kept close enough to the cutting blade 24 to reduce the twist of the cutting blade 24 because the cutting blade 24 can be prevented from twisting (or twisting to such a degree) due to the hardened portions 312 that can at least partially obstruct the sides 308 of the twisting cutting blade 24.

It will be appreciated in light of the disclosure that twisting can be due to forces between the cutting blade 24 and the workpiece 36 and not otherwise due to an optionally implemented scrolling functionality that can impart a twist on the cutting blade 24 to, among other things, make it relatively easier to turn the cutting blade in decorative cutting with the jigsaw.

While specific aspects have been described in the specification and illustrated in the drawings, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements and components thereof without departing from the scope of the present teachings, as defined in the claims. Furthermore, the mixing and matching of features, elements, components and/or functions between various aspects of the present teachings are expressly contemplated herein so that one skilled in the art will appreciate from the present teachings that features, elements, components and/or functions of one aspect of the present teachings can be incorporated into another aspect, as appropriate, unless described otherwise above. Moreover, many modifications may be made to adapt a particular situation, configuration or material to the present teachings without departing from the essential scope thereof. Therefore, it is intended that the present teachings not be limited to the particular aspects illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out the present teachings, but that the scope of the present teachings include many aspects and examples following within the foregoing description and the appended claims. 

1. A method of positioning a shoe member and a keel assembly relative to a housing of a jigsaw, the method comprising: securing the keel assembly to the housing so that the keel assembly extends from the housing beyond the shoe member; pivoting the housing and the keel assembly relative to the shoe member in a manner such that a position of the housing relative to the keel assembly remains unchanged; and uncoupling a portion of the keel assembly from the housing.
 2. The method of claim 1, wherein uncoupling a portion of the keel assembly from the housing includes removing the keel assembly from the housing.
 3. The method of claim 2, wherein removing the keel assembly includes moving an actuator member of a latch assembly to release a front portion of the keel assembly.
 4. The method of claim 3, further comprising pivoting the keel assembly about a rear portion of the housing when the front portion of the keel assembly is released from the housing by moving the actuator member.
 5. The method of claim 3, wherein moving the actuator member is performed without a tool.
 6. The method of claim 1, further comprising moving a lower carrier assembly relative to the keel assembly and the housing between at least two positions.
 7. The method of claim 6, wherein the keel assembly includes a keel blade member and the lower carrier assembly includes a lower blade guide and an adjuster member connected to a cam surface, and wherein the method further comprises moving the adjuster member between a retracted position and an extended position, wherein the cam surface is not obstructed by an edge of a groove formed in the keel blade member when the adjuster member is in the retracted position so that a position of the lower carrier assembly can be adjusted, and wherein the cam surface is returned to a position that is obstructed by the edge of the groove in the extended position.
 8. A method of positioning a keel assembly and a lower carrier assembly relative to a housing of a jigsaw, the lower carrier assembly having a lower blade guide, the method comprising: connecting the keel assembly to the housing so that the keel assembly extends from the housing beyond a shoe member; pivoting the keel assembly relative to the housing; and adjusting a position of the lower carrier assembly relative to the keel assembly.
 9. The method of claim 8, further comprising removing the keel assembly from the housing.
 10. The method of claim 9, wherein removing the keel assembly includes moving an actuator member of a latch assembly to release the front portion of the keel assembly.
 11. The method of claim 10, wherein moving the actuator member is performed without a tool.
 12. The method of claim 8, wherein the keel assembly includes a keel blade member and the lower carrier assembly includes an adjuster member connected to a cam surface, and wherein the method further comprises moving the adjuster member between a retracted position and an extended position, wherein the cam surface is not obstructed by an edge of a groove formed in the keel blade member when the adjuster member is in the retracted position so that a position of the lower carrier assembly can be adjusted, and wherein the cam surface is returned to a position that is obstructed by the edge of the groove in the extended position.
 13. The method of claim 8, further comprising positioning the blade member and the keel assembly at a non-perpendicular angle relative to the shoe member.
 14. The method of claim 8, wherein the jigsaw includes an upper blade guide adapted to cooperate with the lower blade guide to support a blade member, and wherein adjusting a position of the lower carrier assembly relative to the keel assembly includes adjusting a position of the lower blade guide relative to the upper blade guide.
 15. A method comprising: providing a jigsaw having a housing, a shoe member, and a keel assembly, the shoe member being coupled to the housing and being adapted to support the jigsaw on a surface of a workpiece, the keel assembly extending from the housing beyond the shoe member; connecting a carrier assembly to the keel assembly, the carrier assembly having a lower blade guide that is adapted to support a blade member; moving the carrier assembly relative to the keel assembly from a first position to a second position; and securing the carrier assembly to the keel assembly in the second position.
 16. The method of claim 15, further comprising uncoupling the keel assembly from the housing.
 17. The method of claim 16, wherein uncoupling the keel assembly includes moving an actuator member of a latch assembly to release a front portion of the keel assembly.
 18. The method of claim 15, wherein the keel assembly includes a keel blade member and the lower carrier assembly includes an adjuster member connected to a cam surface, and wherein the method further comprises moving the adjuster member between a retracted position and an extended position, wherein the cam surface is not obstructed by an edge of a groove formed in the keel blade member when the adjuster member is in the retracted position so that a position of the lower carrier assembly can be adjusted, and wherein the cam surface is returned to a position that is obstructed by the edge of the groove in the extended position.
 19. The method of claim 15, further comprising positioning the blade member and the keel assembly at a non-perpendicular angle relative to the shoe member.
 20. The method of claim 15, wherein the jigsaw includes an upper blade guide adapted to support the blade member, and wherein moving the carrier assembly relative to the keel assembly includes moving the lower blade guide relative to the upper blade guide. 